| CPC B22F 1/10 (2022.01) [B22F 1/05 (2022.01); B22F 1/102 (2022.01); B22F 1/16 (2022.01); B22F 10/10 (2021.01); B22F 10/14 (2021.01); B22F 10/73 (2021.01); B29C 64/165 (2017.08); B33Y 10/00 (2014.12); B33Y 40/10 (2020.01); B33Y 70/10 (2020.01); C08F 2/22 (2013.01); C08F 212/08 (2013.01); C08F 220/14 (2013.01); C08K 3/11 (2018.01); C09D 11/037 (2013.01); C09D 11/322 (2013.01); C09D 11/38 (2013.01); B22F 10/28 (2021.01); B22F 2304/10 (2013.01); B22F 2998/10 (2013.01); B82Y 30/00 (2013.01)] | 15 Claims |
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1. A build material composition, comprising:
a host metal powder present in an amount ranging from about 95.00 weight percent to about 99.99 weight percent, based on a total weight of the composition, the host metal powder including host metal particles having an average particle size of less than 20 micrometers and the host metal powder having a sintering temperature of from about 500° C. to about 1800° C.; and
a flow additive present in an amount ranging from about 0.01 weight percent to about 5.00 weight percent, based on the total weight of the composition, wherein the flow additive consists of particles of a freeze-dried organic material that is pyrolyzable at a pyrolysis temperature that is less than the sintering temperature of the host metal powder,
wherein the particles of the freeze-dried organic material include a heteropolymer having a hydrophobic component that makes up from about 65% by weight to about 99.9% by weight of the heteropolymer and a hydrophilic component that makes up from about 0.1% by weight to about 35% by weight of the heteropolymer with the hydrophobic component having a lower glass transition temperature compared to the hydrophilic component, wherein:
the hydrophobic component is formed from a monomer selected from the group consisting of ethyl acrylate, ethyl methacrylate, propyl acrylate, propyl methacrylate, hydroxyethyl acrylate, octadecyl methacrylate, tetrahydrofurfuryl acrylate, alkoxylated tetrahydrofurfuryl acrylate, 2-phenoxyethyl methacrylate, benzyl acrylate, ethoxylated nonyl phenol methacrylate, cyclohexyl methacrylate, trimethyl cyclohexyl methacrylate, t-butyl methacrylate, n-octyl methacrylate, tridecyl methacrylate, isodecyl acrylate, dimethyl maleate, dioctyl maleate, acetoacetoxyethyl methacrylate, diacetone acrylamide, vinyl chloride, vinylidene chloride, N-vinyl imidazole, N-vinylcarbazole, N-vinyl-caprolactam, and combinations thereof; and
the hydrophilic component is formed from an acidic monomer selected from the group consisting of ethacrylic acid, dimethylacrylic acid, maleic anhydride, maleic acid, vinylsulfonate, cyanoacrylic acid, vinylacetic acid, allylacetic acid, ethylidineacetic acid, propylidineacetic acid, crotonoic acid, fumaric acid, itaconic acid, sorbic acid, angelic acid, cinnamic acid, styrylacrylic acid, citraconic acid, glutaconic acid, aconitic acid, phenylacrylic acid, acryloxypropionic acid, aconitic acid, phenylacrylic acid, acryloxypropionic acid, vinylbenzoic acid, N-vinylsuccinamidic acid, mesaconic acid, methacroylalanine, acryloylhydroxyglycine, sulfoethyl methacrylic acid, sulfopropyl acrylic acid, styrene sulfonic acid, sulfoethylacrylic acid, 2-methacryloyloxymethane-1-sulfonic acid, 3-methacryoyloxypropane-1-sulfonic acid, 3-(vinyloxy)propane-1-sulfonic acid, ethylenesulfonic acid, vinyl sulfuric acid, 4-vinylphenyl sulfuric acid, ethylene phosphonic acid, vinyl phosphoric acid, vinyl benzoic acid, 2 acrylamido-2-methyl-1-propanesulfonic acid, and combinations thereof, and wherein the composition is spreadable, having a Hausner Ratio less than 1.25.
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